Stress buffer structures in a mounting structure of a semiconductor device

ABSTRACT

A semiconductor device includes a bonding pad on a substrate. The semiconductor device further includes a passivation layer covering a peripheral portion of the bonding pad while exposing a middle portion of the bonding pad. Additionally, the semiconductor device includes a stress buffer layer over the passivation layer where the stress buffer layer exposes a portion of the bonding pad, and where a wall of the stress buffer layer extends, in steps, upwardly from the exposed portion of the bonding pad. Furthermore, the semiconductor device includes an under-bump metallurgy (UBM) layer over the stress buffer layer, where the UBM layer contacts a portion of the bonding pad.

PRIORITY CLAIM

The present application is a continuation of U.S. application Ser. No. 13/714,828, filed Dec. 14, 2012, which is a divisional application of U.S. application Ser. No. 12/697,473 filed Feb. 1, 2010, now U.S. Pat. No. 8,354,750, issued Jan. 15, 2103, the disclosures of which are incorporated by reference herein in their entireties.

TECHNICAL FIELD

The present disclosure relates to stress buffer structures for a mounting structure of a semiconductor device.

BACKGROUND

Recently, there has been a trend in miniaturizing integrated circuits (ICs), requiring a high I/O (input/output) density which, in turn, requires small-size bonding pads. Such bonding pads are often formed on the active surface of a chip and define the places where the circuits of the chip are electrically connected to external devices. Bonding wires have become increasingly unpopular due to various potential problems, such as short circuits or inconsistent or inadequate bond strengths. Therefore, a flip chip technique has been introduced. According to this technique, solder bumps are formed on bonding pads of a chip, and the chip is mounted directly on a substrate by reflowing the solder bumps. The final product is often referred to as a ball grid array (BGA) or a flip chip ball grid array (FCBGA) chip or package.

To promote adhesion between the solder bump and the bonding pad, an under bump metallurgy or under bump metallization (UBM) structure is interposed between the solder bump and the bonding pad. UBM structures can also perform other functions, for example, as a barrier for preventing diffusion of the solder material into the bonding pad or even into the semiconductor material of the chip. A typical UBM structure includes several metal layers each performing a desired function.

Due to the concentration of multiple material layers of a UBM structure and a solder bump at and in the vicinity of each bonding pad, there is also a concentration of stress in this area. Such a stress, without preventive measure, may become sufficiently large to cause damage to inter-level dielectric (ILD) layers of the chip that are located immediately below or adjacent the bonding pad. Particularly sensitive to stress are low-k (low dielectric constant material) layers which are brittle and, in some applications, porous. Such low-k layers are easy to crack and/or delaminate under stress.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments are illustrated by way of example, and not by limitation, in the figures of the accompanying drawings, wherein elements having the same reference numeral designations represent like elements throughout. The drawings are not to scale, unless otherwise disclosed.

FIG. 1 is a schematic, cross-sectional view of a solder bump structure in a semiconductor device.

FIGS. 2A-2C are schematic, simplified cross-sectional views of several bonding structures for the solder bump structure.

FIGS. 3A-3B are graphs comparing stress distributions and stress values, respectively, in the bonding structures of FIGS. 2A-2C.

FIGS. 4A-4H are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device according to some embodiments.

FIGS. 5A-5D are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device according to further embodiments.

FIGS. 6A-6B are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device according to yet further embodiments.

FIGS. 7A-7C are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device according to still further embodiments.

FIGS. 8A-8C are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device according to some other embodiments.

DETAILED DESCRIPTION

Throughout the description presented below, it will be understood that when a layer is referred to as being ‘on’ or ‘over’ another layer or substrate, it can be in direct contact with the other layer or substrate, or intervening layers may also be present therebetween.

FIG. 1 is a schematic, cross-sectional view of a solder bump structure 100 known to the inventors. Solder bump structure 100 is formed on an active surface 101 of a wafer or chip 102 of a semiconductor device, and includes a first passivation layer 106, a bonding pad 108, a second passivation layer 110, a PI (polyimide) layer 112, a UBM structure 114 and a solder bump 116 formed one on top another in the recited order. Chip 102 includes, under bonding pad 108, a top-level metal 104 electrically connected to bonding pad 108. The top-level metal 104 is a portion of an interconnection structure within chip 102. The interconnection structure of chip 102 further includes, under and/or in the vicinity of top-level metal 104, one or more dielectric layers (not shown) which, as discussed above, are often made of low-k or extreme low-k materials that are brittle and susceptible to cracks or delamination.

The inventors have found that solder bump structure 100 generally creates a high stress concentration at upper and lower corners 120, 122 of UBM structure 114. The stress distribution depends, among other things, on the inclination angle of a sidewall 1149 of UBM structure 114. Specifically, the inventors have discovered that at a relatively acute inclination angle (e.g., 40° with respect to active surface 101) of sidewall 1149, stress is largely concentrated around lower corner 120. As the inclination angle of sidewall 1149 increases toward 90°, the stress concentration shifts towards upper corner 122. However, at any inclination angle, high stress is still transmitted to the dielectric layers of the interconnection structure underneath corners 120, 122 and increases the possibility of cracks in or delamination of the dielectric layers.

FIG. 2A is a simplified or partial view of solder bump structure 100 of FIG. 1. FIGS. 2B-2C are views similar to FIG. 2A and show solder bump structures 240, 250 in accordance with various embodiments.

Specifically, solder bump structure 240 of FIG. 2B is formed on an active surface 201 of a semiconductor wafer or chip (not shown) of a semiconductor device. Solder bump structure 240 includes a bonding pad 208, a stress buffer structure 212, a UBM structure 214 and a solder bump 216 (partially shown) formed one on top another in the recited order. Under bonding pad 208, the chip includes an interconnection structure comprising multiple conductive and dielectric layers alternatingly arranged one on top another. For the sake of simplicity, only a top-level conductive layer, e.g., a top metal layer, 204 of the interconnection structure is shown in the figure. The interconnection structure further includes, under and/or in the vicinity of top metal 204, one or more dielectric layers (not shown) which, in some embodiments, are made of low-k or extreme low-k materials. Solder bump structure 240 defines a mounting structure for the chip when the chip is flipped over and placed on a carrier, such as a substrate or lead frame (not shown) and solder bump 216 is re-flown. In some embodiments, the chip comprises multiple bonding pads 208 for which multiple solder bump structures 240 are provided.

Stress buffer structure 212 defines a distinction from PI layer 112 of solder bump structure 100 in FIGS. 1 and 2A. In particular, PI layer 112 has a sidewall 1125 that monotonously extends upward from bonding pad 108, i.e., sidewall 1125 extends at a uniform slope from the bonding pad. As a result, UBM structure 114 formed on PI layer 112 and conforming in shape to PI layer 112 also has monotonously extending sidewall 1149. Such solder bump structure 100, as discussed above, is likely to cause stress concentration on the underlying layers, such as low-k or extremely low-k dielectric layers, of the chip.

To the contrary, stress buffer structure 212 of solder bump structure 240 in FIG. 2B does not have a monotonously extending sidewall. Instead, sidewall 2125 of stress buffer structure 212 extends in a stepwise manner upwardly from bonding pad 208. Sidewall 2125 includes at least two steps above the level of bonding pad 208, namely lower step 2121 and upper step 2122 which have respective heights b and a as exemplarily depicted in FIG. 2B. Since sidewall 2125 of stress buffer structure 212 is stepwise, UBM structure 214, which is formed on stress buffer structure 212 and conforms in shape to stress buffer structure 212, also has a stepwise sidewall 2149. As discussed in detail herein below, the stepwise configuration of UBM structure 214 and stress buffer structure 212 results in a more uniform distribution of stress on the underlying layers, such as low-k or extremely low-k dielectric layers. The stepwise configuration further reduces the maximum and/or average values of stress compared to solder bump structure 100.

Solder bump structure 250 in FIG. 2C is similar to solder bump structure 240, except for the height ratio between steps, such as lower step 2121 and upper step 2122. The particular illustrated configuration in FIG. 2B has an approximately 1:1 height ratio, i.e., the height b of lower step 2121 and the height of upper step 2122 are about the same. The particular illustrated configuration in FIG. 2C has an approximately 2:1 height ratio, i.e., upper step 2122 is about twice as high as lower step 2121.

Assuming that all characteristics (i.e., materials, thicknesses etc.) of solder bump structures 100, 240 and 250 are the same, except for the particular shapes and the particular height ratios (applicable to FIGS. 2B-2C) of PI layer 112/stress buffer structure 212 and corresponding UBM structures, the results of performing a computer simulation of stress generation are shown in FIGS. 3A-3B.

FIG. 3A is a graph of stress distribution in the underlying low-k or extremely low-k dielectric (ELK) materials, e.g., under top metal layers 104, 204, in solder bump structures 100, 240 and 250. The stress distribution of solder bump structure 100 in FIG. 2A is most uneven, having very high peaks (maximum stress values) at locations corresponding to lower corners 120 (FIG. 1). The stress distribution of solder bump structure 240 in FIG. 2B is more uniform than that of solder bump structure 100 in FIG. 2A, having lower high peaks. The stress distribution of solder bump structure 250 in FIG. 2C is even more uniform that that of solder bump structure 240 in FIG. 2B, having even lower high peaks. As a result, the maximum stress values are reduced from solder bump structure 100 down to solder bump structure 240 and further down to solder bump structure 250. Thus, high stress concentrations are less severe in solder bump structure 240 and solder bump structure 250 than in solder bump structure 100.

The average stress values are also improved. FIG. 3B is a graph showing average stress values in the underlying low-k or extremely low-k dielectric (ELK) materials, e.g., under top metal layers 104, 204, and in the overlying UBM structures, such as UBM structures 114, 214. As apparent from FIG. 3B, average stress values, across the width of the UBM structure, in both the underlying dielectric materials and the UBM structures decrease from solder bump structure 100 to solder bump structure 240 and further to solder bump structure 250. The average stress value in the underlying dielectric materials is reduced more than 25% (from 63.4 to 47.1) and the average stress value in the UBM structure is reduced for about 20% (from 183.3 to 147.1).

Thus, the stepwise configuration of the UBM structure and the stress buffer structure results in more uniform stress distribution and lower maximum/average stress values in both the underlying dielectric materials of the chip and in the UBM structure itself. In numerous unshown embodiments, by varying the number of steps (e.g., forming more than two steps) and/or the heights and/or height ratios among the steps of such stepwise configuration, stress values and distributions in the UBM structure as well as the underlying dielectric materials of the chip can be optimized as desired. Such stress optimization is performed either independently of or in combination with other adjustments, such as the thickness of the stress buffer structure (also referred to as “PI thickness” in some embodiments) and/or the size of the opening in the stress buffer structure (also referred to as “PI opening” in some embodiments) and/or the inclination angle of the sidewall of the opening.

Stress buffer structure 212 includes one or more material layers. For simplicity, only one layer of stress buffer structure 212 is shown in FIGS. 2B-2C. Such layer is made of a stress buffer material and defines stepwise wall 2125 of stress buffer structure 212 and, hence, corresponding stepwise wall 2149 of UBM structure 214. The stress buffer material in some embodiments is a polymer. The polymer in one or more embodiments is selected from the group consisting of polyimide, polybenzoxazole (PBO), epoxy-based polymers, phenol-based polymers, and benzocyclobutene (BCB).

In some embodiments, a passivation layer (not shown in FIGS. 2B-2C) similar to second passivation layer 110 of solder bump structure 100 is provided under stress buffer structure 212 to adjust the height of stress buffer structure 212 without requiring a large amount of the stress buffer material. In further embodiments, multiple layers of one or more stress buffer materials are deposited on top the other to define stress buffer structure 212, either entirely or in combination with a passivation layer.

FIGS. 4A-4H are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device 400 (FIG. 4H) according to some embodiments.

In FIG. 4A, a semiconductor substrate 402 is provided. Semiconductor substrate 402 is, in some embodiments, a wafer. In further embodiments, semiconductor substrate 402 is a chip having internal circuitry and active surface 401. Semiconductor substrate 402 includes a top-level conductive layer, e.g., a top metal layer 404. Semiconductor substrate 402 further includes, under and/or in the vicinity of top metal 404, one or more dielectric layers (not shown) which are, in some embodiments, made of low-k or extremely low-k materials that are brittle and susceptible to cracks or delamination.

A first passivation layer 406 is formed on active surface 401 to partially cover top metal layer 404. The part of top metal layer 404 that is not covered by first passivation layer 406 is exposed in a first opening also referred to herein as the first passivation opening. Passivation layer 406 in some embodiments comprises an oxide layer or a nitride layer, such as silicone oxide or silicon nitride. In further embodiments, first passivation layer 406 comprises polyimide. An exemplary process of forming first passivation layer 406 includes depositing (e.g., by chemical vapor deposition—CVD) a passivation material on active surface 401 and then etching away a portion of the passivation material to form the first passivation opening.

A conductive material is subsequently deposited in the first passivation opening, and on a top surface of first passivation layer 406 around the first passivation opening to form a bonding pad 408. In some embodiments, bonding pad 408 is confined within the first passivation opening, without being deposited on the top surface of first passivation layer 406. The conductive material of bonding pad 408 comprises Al or Cu and is deposited to be in electrical contact (e.g., via a conductive via) with the internal circuitry of semiconductor substrate or chip 402.

A passivation material layer 4101 is deposited on bonding pad 408 and first passivation layer 406 as shown in FIG. 4A. Passivation material layer 4101 in the particularly illustrated embodiment has a top surface conforming in shape to the underlying bonding pad 408. In further embodiments, the top surface of passivation material layer 4101 is planarized prior to subsequent processing. Passivation material layer 4101 is made of the same as or similar material to first passivation layer 406.

In FIG. 4B, a mask 411 having an opening D1 is used to partially remove an exposed portion of passivation material layer 4101. For example, mask 411 comprises a photoresist deposited and then photo-lithographically patterned on the top surface of passivation material layer 4101. The removal of passivation material layer 4101 is performed by, e.g., a first etching process.

FIG. 4C shows the result of the first etching process and after mask 411 is removed. Specifically, a second passivation opening 4159 is formed in passivation material layer 4101. The once patterned passivation material layer 4101 will be referred to herein as passivation material layer 4102. In some embodiments, as shown in FIG. 4C, the etching of passivation material layer 4101 stops before bonding pad 408 is exposed. Consequently, a stepwise configuration with at least three steps will be obtained as disclosed herein below. In other embodiments, the etching of passivation material layer 4101 is performed until bonding pad 408 is exposed. As a result, a stepwise configuration with at least two steps will be obtained.

In FIG. 4D, a further mask 413 having an opening D2 greater than D1 is used to further remove, e.g., by a second etching process, an exposed portion of passivation material layer 4102. For example, mask 413 is formed similarly to mask 411.

FIG. 4E shows the result of the second etching process and after mask 413 is removed. Specifically, second passivation opening 4159 is enlarged and denoted as 4160. The twice patterned passivation material layer 4101 has now become a second passivation layer 410. As shown in FIG. 4E, second passivation layer 410 has a stepwise wall 4107. The second etching process of passivation material layer 4102 is performed until bonding pad 408 is exposed.

FIG. 4E shows the result of the second etching process and after mask 413 is removed. Specifically, second passivation opening 4159 is enlarged and now denoted as 4160. The twice patterned passivation material layer 4101 has now become a second passivation layer 410. As shown in FIG. 4E, second passivation layer 410 has a stepwise wall 4107.

In FIG. 4F, a stress buffer material layer 4121 is deposited, e.g., by spin-coating, on second passivation layer 410, in second passivation opening 4160 and on the exposed portion of bonding pad 408. A sidewall 4125 of stress buffer material layer 4121 has two upper steps conforming in shape to stepwise wall 4107 of second passivation layer 410. Sidewall 4125 of stress buffer material layer 4121 further has a lower step conforming in shape to a raised portion 4083 of bonding pad 408.

In FIG. 4G, the portion of stress buffer material layer 4121 at the bottom of second passivation opening 4160 is removed to expose a portion of bonding pad 408, using, for example, well-known patterning methods including photolithography and etching processes. The so formed and patterned stress buffer material layer 4121 has now become a stress buffer structure 412 having a stepwise configuration with three steps.

In FIG. 4H, an UBM structure 414 is deposited on stress buffer structure 412, conforming in shape to stress buffer structure 412 and in electrical contact with the exposed portion of bonding pad 408. UBM structure 414 includes one or more layers of at least one metal selected from the group consisting of Cr, Ti, Ni, W, Pt, Cu, Pd, Au, Ag and alloys thereof. UBM structure 414 is formed by sequentially depositing, e.g., by CVD, plating or sputtering, the component layers on bonding pad 408, and then etching away, e.g., by dry etching or wet etching, the unwanted portions. A solder bump 416 is formed on UBM structure 414 to complete semiconductor device 400.

FIGS. 5A-5D are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device 500 (FIG. 5D) according to some embodiments.

In FIG. 5A, a semiconductor substrate 502 similar to semiconductor substrate 402 is provided. Semiconductor substrate 502 includes a top-level conductive layer, e.g., a top metal layer 504 similar to top metal layer 404. A first passivation layer 506, a bonding pad 508 and a passivation material layer 5101 similar to first passivation layer 406, bonding pad 408, passivation material layer 4101, respectively, are formed on semiconductor substrate 502 in manners substantially similar to those described with respect to FIG. 4A.

A difference between FIGS. 5A and 4A is that in FIG. 5A, first passivation layer 506 is patterned more than once, e.g., twice, whereas in FIG. 4A, first passivation layer 406 is patterned once. As the result the first passivation opening in first passivation layer 506 has a stepwise sidewall as shown in FIG. 5A. An exemplary process of forming the stepwise first passivation opening is similar to that described with respect to FIGS. 4B-4E, e.g., by two etching processes with two differently sized masks. Other methods are, however, not excluded.

A further difference between FIGS. 5A and 4A is that bonding pad 508 formed on and conforming in shape to underlying first passivation layer 506 also has a stepwise configuration. Specifically, bonding pad 508 has a lower step 5081 and an upper step 5082 corresponding to a lower step 5061 and an upper step 5062 of first passivation layer 506, respectively. In some embodiments (not shown), bonding pad 508 is confined within a boundary defined by upper step 5062 of first passivation layer 506, and therefore has a configuration similar to that of FIG. 4A.

In FIG. 5B, a mask 511 similar to mask 411 and having an opening D3 is used to remove an exposed portion of passivation material layer 5101, in a manner similar to that described with respect to FIG. 4B.

FIG. 5C shows the result of the etching process of FIG. 5B and after mask 511 is removed. Specifically, a second passivation opening 5159 is formed in the once patterned passivation material layer 5101 which has now become second passivation layer 510. The etching of passivation material layer 5101 stops upon or after bonding pad 508 is exposed. A top surface of upper step 5082 of bonding pad 508 is buried in second passivation layer 510, and therefore a stepwise configuration with at least two steps will be obtained as disclosed herein below.

In FIG. 5D, a stress buffer material layer is deposited and patterned to define stress buffer structure 512 in manners similar to those described with respect to FIGS. 4F-4G. A sidewall 5125 of stress buffer material layer 512 has an upper step 5127 corresponding to a top surface of second passivation layer 510, and a lower step 5128 corresponding to lower step 5081 of bonding pad 508.

An UBM structure 514 is deposited on stress buffer structure 512, conforming in shape to stress buffer structure 512 and in electrical contact with the exposed middle portion of bonding pad 508 in manners similar to those described with respect to FIG. 4H. A solder bump (not shown in FIG. 5D) is formed on UBM structure 514 to complete semiconductor device 500.

FIGS. 6A-6B are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device 600 (FIG. 6B) according to some embodiments.

FIG. 6A is a continuation to the step of FIG. 5C, in that a mask 613 having an opening D4 greater than D3 is used for further etching second passivation layer 510 to obtain stress buffer structure 612 (FIG. 6B). Thus, the second passivation opening 5159 in FIG. 5C is widened, and as a result, a top surface of upper step 5082 of bonding pad 508 is exposed, and defines a further step of the final stepwise configuration shown in FIG. 6B.

Specifically, in FIG. 6B, a sidewall 6125 of stress buffer material layer 612 has an upper step 6127 corresponding to a top surface of second passivation layer 610, a lower step 6128 corresponding to lower step 5081 of bonding pad 508, and a middle step 6129 corresponding to the top surface of upper step 5082 of bonding pad 508.

An UBM structure 614 is deposited on stress buffer structure 612, conforming in shape to stress buffer structure 612 and in electrical contact with the exposed middle portion of bonding pad 508 in manners disclosed herein. A solder bump (not shown in FIG. 6B) is formed on UBM structure 614 to complete semiconductor device 600.

In some embodiments, mask 613 is used instead of, rather than in combination with, mask 511 to etch passivation material layer 5101 as shown in FIG. 5B, to obtain a semiconductor device similar to semiconductor device 600.

FIGS. 7A-7C are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device 700 (FIG. 7C) according to some embodiments.

FIG. 7A shows a state of the semiconductor device as being manufactured by several processes similar to those disclosed with respect to FIGS. 4A-4C and 4F-4H. Specifically, a semiconductor substrate 702 in FIG. 7A is similar to semiconductor substrate 402. Semiconductor substrate 702 includes a top-level conductive layer, e.g., a top metal layer 704 similar to top metal layer 404. A first passivation layer 706, a bonding pad 708 and a passivation material layer (not shown) similar to first passivation layer 406, bonding pad 408, passivation material layer 4101, respectively, are formed on semiconductor substrate 702 in manners substantially similar to those described with respect to FIG. 4A.

The passivation material layer is patterned with a mask similar to that described with respect to FIG. 4B.

The patterning of the passivation material layer, unlike the process particularly shown in FIG. 4C, is performed until the middle portion of bonding pad 708 is exposed, thereby obtaining a second passivation layer 710.

A stress buffer material layer (not shown) is deposited on the patterned second passivation layer 710 as described with respect to FIG. 4F, and patterned as described with respect to FIG. 4G, thereby obtaining a patterned stress buffer material layer 7121 as illustrated in FIG. 7A.

A mask 711 similar to mask 411 and having an opening (not numbered) wider than that of second passivation opening 7159 formed in second passivation layer 710 is used to remove a partial thickness of an exposed portion of patterned stress buffer material layer 7121 around second passivation opening 7159 to obtain a stress buffer structure 712 as shown in FIG. 7B.

FIG. 7B shows the result of the etching process of FIG. 7A and after mask 711 is removed. Specifically, the partial thickness removal of patterned stress buffer material layer 7121 creates a stepwise wall 7125 for stress buffer structure 712. In particular, sidewall 7125 of stress buffer material layer 712 has an upper step 7127 corresponding to a top surface of patterned stress buffer material layer 7121 before the second etching process, and a lower step 7128 corresponding to a top surface of the stress buffer material layer 7121 around second passivation opening 7159 after the second etching process. Thus, a stepwise configuration of two steps is obtained.

In FIG. 7C, an UBM structure 714 is deposited on stress buffer structure 712, conforming in shape to stress buffer structure 712 and in electrical contact with the exposed middle portion of bonding pad 708 in manners similar to those described with respect to FIG. 4H. A solder bump (not shown in FIG. 7C) is formed on UBM structure 714 to complete semiconductor device 700.

FIGS. 8A-8C are schematic cross-sectional views showing various steps of manufacturing a bonding structure for a semiconductor device 800 (FIG. 8C) according to some embodiments.

FIG. 8A is similar to FIG. 7A, without mask 711. Thus, a semiconductor substrate 802 in FIG. 8A is similar to semiconductor substrate 702. Semiconductor substrate 802 includes a top-level conductive layer, e.g., a top metal layer 804 similar to top metal layer 704. A first passivation layer 806, a bonding pad 808, a second passivation layer 810 and a patterned stress buffer material layer 8121 similar to first passivation layer 706, bonding pad 708, second passivation layer 710 and patterned stress buffer material layer 7121, respectively, are formed on semiconductor substrate 802 in manners disclosed herein. A second passivation opening 8159 similar to second passivation opening 7159 is also formed.

In FIG. 8B, instead of immediately etching the structure shown in FIG. 8A with a mask as discussed with respect to FIG. 7A, a second stress buffer material layer 8122 is filled in second passivation opening 8159 and deposited to a desired thickness on patterned stress buffer material layer 8121. A spin-coating process is used in some embodiments for forming such second stress buffer material layer 8122. A mask 811 of a desired opening (not numbered) is then used to etch away the exposed portion of second stress buffer material layer 8122 in second passivation opening 8159 and on top of patterned stress buffer material layer 8121. The etch selectivity of stress buffer materials of patterned stress buffer material layer 8121 and second stress buffer material layer 8122 is chosen such that the exposed portion of second stress buffer material layer 8122 is removed without significantly effecting the thickness of patterned stress buffer material layer 8121 within the opening of mask 811.

FIG. 8C shows the result of the etching process of FIG. 8B and after mask 811 is removed. A stress buffer structure 812, which is a combination of a remainder of second stress buffer material layer 8122 and patterned stress buffer material layer 8121, is obtained with a stepwise wall 8125. Sidewall 8125 of stress buffer material layer 812 has an upper step 8127 corresponding to a top surface of second stress buffer material layer 8122 and a lower step 8128 corresponding to a top surface of patterned stress buffer material layer 8121. Thus, a stepwise configuration of two steps is obtained. The height ratio of the steps of the stepwise configuration can be adjusted by simply adjusting the thickness of second stress buffer material layer 8122 in relation to a depth of second passivation opening 8159 (FIG. 8A).

An UBM structure 814 is deposited on stress buffer structure 812, conforming in shape to stress buffer structure 812 and in electrical contact with the exposed middle portion of bonding pad 808 in manners similar to those described with respect to FIG. 4H. A solder bump (not shown in FIG. 8C) is formed on UBM structure 814 to complete semiconductor device 800.

In some embodiments, a semiconductor device includes a bonding pad on a substrate. The semiconductor device further includes a passivation layer covering a peripheral portion of the bonding pad while exposing a middle portion of the bonding pad. Additionally, the semiconductor device includes a stress buffer layer over the passivation layer where the stress buffer layer exposes a portion of the bonding pad, and where a wall of the stress buffer layer extends, in steps, upwardly from the exposed portion of the bonding pad. Furthermore, the semiconductor device includes an under-bump metallurgy (UBM) layer over the stress buffer layer, where the UBM layer contacts a portion of the bonding pad.

In some embodiments, a semiconductor device includes a metal layer embedded in a substrate. The semiconductor device further includes a passivation layer over the metal layer where the passivation layer exposes a portion of the metal layer, and the passivation layer includes a stepped wall that extends upwardly from the exposed portion of the metal layer. Furthermore, the semiconductor device includes a bonding pad over the exposed portion of the metal layer. Additionally, the semiconductor device includes an under-bump metallurgy (UBM) layer over the bonding pad.

In some embodiments, a semiconductor device includes a bonding pad on a substrate. The semiconductor device further includes a stress buffer structure over the bonding pad where the stress buffer structure exposes a portion of the bonding pad and where the stress buffer structure comprises a stepped wall that extends upwardly from the exposed portion of the bonding pad. Additionally, the semiconductor device includes an under-bump metallurgy (UBM) layer over the bonding pad, where the UBM layer contacts a portion of the bonding pad.

The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the detailed description that follows. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for modifying other processes and structures for carrying out one or more of the same or similar purposes and/or achieving one or more of the same or similar advantages of the embodiments disclosed herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure. 

What is claimed is:
 1. A semiconductor device, comprising: a bonding pad on a substrate; a passivation layer covering a peripheral portion of the bonding pad while exposing a middle portion of the bonding pad; a stress buffer layer over the passivation layer, the stress buffer layer exposing a portion of the bonding pad, wherein a wall of the stress buffer layer extends, in steps, upwardly from the exposed portion of the bonding pad; and an under-bump metallurgy (UBM) layer over the stress buffer layer, wherein the UBM layer contacts a portion of the bonding pad.
 2. The semiconductor device according to claim 1, wherein the stress buffer polymer layer comprises polyimide, polybenzoxazole (PBO), epoxy-based polymers, phenol-based polymers, or benzocyclobutene (BCB).
 3. The semiconductor device of claim 1, wherein the wall of the stress buffer layer comprises an upper step and a lower step, wherein the upper step and the lower step have equal lengths.
 4. The semiconductor device of claim 1, wherein the wall of the stress buffer layer comprises an upper step and a lower step, wherein the upper step has a first length that is greater than a second length of the lower step.
 5. The semiconductor device of claim 1, further comprising a sidewall of the passivation layer conforming to the contours of the wall of the stress buffer layer.
 6. The semiconductor device of claim 1, further comprising the UBM layer conforming to the contours of the wall of the stress buffer layer.
 7. A semiconductor device, comprising: a metal layer embedded in a substrate; a passivation layer over the metal layer, wherein the passivation layer exposes a portion of the metal layer, the passivation layer comprising a stepped wall that extends upwardly from the exposed portion of the metal layer; a bonding pad over the exposed portion of the metal layer; and an under-bump metallurgy (UBM) layer over the bonding pad.
 8. The semiconductor device according to claim 7, wherein the stress buffer polymer layer comprises polyimide, polybenzoxazole (PBO), epoxy-based polymers, phenol-based polymers, or benzocyclobutene (BCB).
 9. The semiconductor device of claim 7, wherein the stepped wall of the passivation layer comprises an upper step and a lower step, wherein the upper step and the lower step have equal lengths.
 10. The semiconductor device of claim 7, wherein the stepped wall of the passivation layer comprises an upper step and a lower step, wherein the upper step has a first length that is greater than a second length of the lower step.
 11. The semiconductor device of claim 7, further comprising the UBM layer conforming to the contours of the passivation layer.
 12. The semiconductor device of claim 7, further comprising a stress buffer layer over the passivation layer.
 13. The semiconductor device of claim 7, further comprising an active region on the periphery of the metal layer.
 14. The semiconductor device of claim 13, wherein a sidewall of the UBM layer forms an acute angle with the active region.
 15. A semiconductor device, comprising: a bonding pad on a substrate; a stress buffer structure over the bonding pad, the stress buffer structure exposing a portion of the bonding pad, wherein the stress buffer structure comprises a stepped wall that extends upwardly from the exposed portion of the bonding pad; and an under-bump metallurgy (UBM) layer over the bonding pad, wherein the UBM layer contacts a portion of the bonding pad.
 16. The semiconductor device according to claim 15, wherein the stress buffer polymer layer comprises polyimide, polybenzoxazole (PBO), epoxy-based polymers, phenol-based polymers, or benzocyclobutene (BCB).
 17. The semiconductor device of claim 15, further comprising a passivation layer surrounding sidewalls of the bonding pad.
 18. The semiconductor device of claim 17, wherein a sidewall of the passivation layer conforms to the contours of the stepped wall of the stress buffer structure.
 19. The semiconductor device of claim 15, wherein the UBM layer conforms to the contours of the stepped wall of the stress buffer layer.
 20. The semiconductor device of claim 15, further comprising a solder bump over the UBM layer. 